Protective clothing system with cooling subsystem

ABSTRACT

A protective clothing system is disclosed that provides cooling via a cooling subsystem. The cooling subsystem can incorporate one or more perforated tubes to provide positive air pressure throughout the clothing system via an external pump. In embodiments, the tubes can be positioned adjacent a spacer mesh product allowing for comfort and unrestricted air flow from the tubing. In various embodiments, the perforated tubing can target specific areas such as the sternum of the chest and the spine region of the back where most of the blood flows in order to cool down the core temperature.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Patent Application No.62/662,461 filed on Apr. 25, 2018, the contents of which areincorporated by reference herein in their entirety

TECHNICAL FIELD

The present disclosure pertains to wearable armor, and more particularlyto comfortable lightweight clothing having ballistic protection.

BACKGROUND

Body armor and helmets are known. In general, it is desirable is to makebody armor and protective headwear as light and as breathable aspossible and still withstand the impact of incoming projectiles. Variousfabric materials have been developed to cause incoming projectiles toexpend energy on the filaments of the fabric, and therefore lose theability to penetrate the person or object being protected by the fabric.Nevertheless, traditional materials suffer from higher than desirableareal densities and thicknesses, and further have proven vulnerable topenetration or meaningful backface deformation (BFD).

With specific reference to helmets, ballistic helmets today aregenerally formed using a monolithic “pinwheel” design. The pinwheeldesign refers to preformed patterns of fabric, where the patternsinclude cuts or seams that are staggered when layered together tominimize structural weakness along any given seam. The layers are thenassembled and secured together, such as with resin, so as to prevent theformation of folds, wrinkles or excessively thick portions.

Early single piece helmet designs have suffered from sub-par ballisticperformance based upon the curve in the material. The more bend orradius in a piece of ballistic material, the worse the ballisticperformance throughout the ballistic solution. Two-piece ballistichelmets have been designed as an exception to this type of singularballistic helmet. However, such designs present challenges with regardto the gap between adjoining shell elements, and further by therecognizable staggered profile in combat situations. Enemy combatantsmay, for example, target personnel wearing the two-piece staggereddesign for strategic purposes.

With regard to body armor, military and law enforcement personnel haveemployed armor-enhanced under-clothing in order to protect their bodiesfrom gunfire, shrapnel, explosive devices and other harmful ballisticobjects. Even when such under-clothing is sized according to individualspecifications (for example, small, medium and large), thearmor-enhanced under-clothing has only a single curve and does notgenerally fit well, gets bunched up, prohibits smooth movement, resultsin undesirable gaps between body and under-clothing, has limited contactpoints with the body, and even hinders the withdrawal of firearms. Forexample, lower abdomen/groin armor components, side torso components,deltoid components, bicep components, and upper leg/thigh components allsuffer from poor ergonomic design. Such disadvantages often result inpoor performance and can encourage mis-use or even non-use of theseprotective devices.

The stiffness in body armor results from material which has a very tightweave or disposition of filaments, for example. Further, armor whichcomprises layers of non-woven fabric stabilized in a matrix resin, isuncomfortable, generally to the degree in which it can stop projectiles.In other words, the more uncomfortable the material, the better withwhich the material can stop the force of projectiles. This stoppingforce is a function of the material's areal density and its flexibility.For the same polymer filaments, the higher the areal density of thefabric, the lower the flexibility and breathability, which translates togreater stopping power. Further, for fabrics made up of the samefilaments, the more non-woven fabric used in a protective compositefabric, the stiffer it is because the matrix resin causes it to haveprogressively fewer void spaces. Solid metal armor such as that worn byknights in past ages is the ultimate in stiffness and lack of voidspaces, with a high areal density of the iron from which it was made. Itis also infinitely stiff, having the same bending ability as any solidmetal armor plate, and is therefore extremely uncomfortable.

In modern body armor, it is desirable to strike a balance between thepower of the garment or fabric to stop an incoming projectile, and thedegree of discomfort borne by the wearer. If the fabric has too fewfilaments, or if the molecular weight and denier of the filaments makingup the fabric is too low, or if the fabric is too thin, there will beinsufficient protection afforded the wearer. Further, as weaponry hasbeen improved, the impact velocity and penetrating power of projectileshas continued to increase, and therefore, the stopping power ofprotective garments has also increased. This has been accomplished byusing stronger and higher molecular weight filaments, by increasing theweight of the fabric, by using a non-woven fabric which has beenstabilized by embedding the fabric in a matrix resin, and by assemblingthe fabric from different elements, such as both woven and non-wovenfabrics, which provide different, and cumulatively superiorly effective,kinds of stopping power. However, along with this need to make theprotective fabric more able to resist the penetration of high energyprojectiles, it is also desired to lighten the fabric and make it morecomfortable to the wearer.

In addition to the above, body armor tends to increase heat generationfrom the wearer's body, with perspiration contributing to the wearer'sdiscomfort and fatigue. Currently, cooling methods for armor wearersinvolve radiator type cooling systems and ice packs. The radiatormethod's drawbacks are weight, real estate, and the need to be poweredwhich limits its effectiveness due to limited battery life. The ice packmethod is heavy, creates bulk, and turns to water that slowly heats uprendering the cooling effect very short lived.

The presently disclosed system and devices overcome the currentshortcomings and more. Embodiments of the present disclosure provide acustomizable, scalable, armor-enhanced under-clothing system thatconforms more substantially to the user's body, providing betterprotection over every critical body area in different stages as selectedby the user. In this way, the user can employ as much or as little ofthe disclosed system as desired or needed for a given anticipated threatlevel, incorporating suitable armor to protect the wearer againstanything from light ballistics (e.g., sand) all the way up to theheaviest ballistic weaponry and fragments that might be encountered.Embodiments of the present disclosure can employ compression fabric as abase material in the top (e.g., shirt) and bottom (e.g., shorts) systemelements, and further can include one or more static fabric materialharnesses in the top and/or bottom elements. The material can beprovided in different forms depending upon desired characteristics(e.g., wicking, fire resistance, temperature management, anti-microbial,etc.). Anti-ballistic panels of suitable material and thickness can beinserted into the static fabric material harness designed to carry thepanels while preventing any undesirable bouncing effect. In embodiments,the top and bottom elements are adapted to be secured to one anotherusing hook-and-loop fasteners or similar fasteners to facilitatecomfort, intended purpose and overall fit. The presently disclosedsystem and devices also provide full body contact as opposed to selectedpoint contact associated with prior devices. The presently disclosedsystem and devices can be provided in sleeveless, short sleeve and longsleeve shirts, shorts and pants, for example.

The present disclosure further reveals body armor and helmets that arelighter weight, easily donned and doffed, provide added comfort andmaintain significant ballistic strength. The present disclosure furtherpertains to a cooling subsystem that can be integrated with thelightweight clothing system to keep the wearer cooler during operation.

In various embodiments, the ballistic helmet of the present disclosureis comprised of two or more pieces, has an areal density of no more than2.10 lbs/ft², and does not exceed a thickness of 0.44 inches whilemaintaining 25 millimeters, or less, backface deformation (BFD) on thehelmet when subject to gunfire. In specific embodiments, the helmetpieces are provided of unidirectional material and are capable ofwithstanding the penetration of at least one of the following projectiletypes: a 9 mm, 124 grain, FMJ projectile impacting the unidirectionalmaterial at a velocity of not less than 1,400 feet per second; and a7.62×39, 124 grain, mild steel core projectile impacting theunidirectional material at a velocity of not less than 2,400 feet persecond. In various embodiments, the unidirectional material can beprovided with an areal density of approximately 1.60 to approximately2.10 pounds per square foot and can comprise not more than 15% by weightof matrix resin. Further, embodiments of the unidirectional material cancomprise from approximately 85 to approximately 100 sub-plies ofunidirectional material joined together by pressing, and wherein theunidirectional material passes the level III-A penetration resistancetest. In various embodiments, the unidirectional material can beprovided with eighty to ninety percent of the material weight in onedirection.

The material employed can be nylon, aramid, or Ultra High MolecularWeight polyethylene (UHMWPE) woven or uni-directional materials, aramidfibers, ceramics, polycarbonate, plastic, aluminum, steel, titanium, ora combination of two or more such materials. The helmet can also besuitably relieved in areas where no ballistic protection is required, orwhere ballistic protection would otherwise impede certain functions ofthe helmet and the wearer's desired functional capabilities.

The multiple pieces of the helmet contribute to the performanceadvantage due to less curvature or bend in the material. Further, themultiple pieces can be joined without a staggered profile and with nogaps in the ballistic solution. In addition to providing multiple piecesto cover the full head of the wearer, each portion of the solution caninclude multiple layers for a full ballistic solution. A base shell orfirst layer can also be provided that includes a chin strap, pads andframe. The second layer can contain the multiple ballistic pieces andthe third layer can provide a hard shell that will marry the base shelland the third layer together containing the ballistic pieces.

With regard to the armor-enhanced under-clothing according to thepresent disclosure, in various embodiments, ancillary body armorcomponents are disclosed that have an areal density of no greater than2.10 lbs/ft² and are no thicker than 0.44 inches while not allowing morethan 50 millimeters of backface deformation (BFD). The ancillary bodyarmor components can be worn in a base-layer and under the uniform.Traditionally, body armor components are worn externally of the uniformso as to speed the donning and doffing process. The base-layer can houseand “suspend” the armor components so as to be positioned correctly andcomfortably with minimal movement and changing of the intended positionon the body in order to enhance overall mobility, extremity movement,and survivability. In various embodiments, an advanced fabric asdisclosed herein houses the armor, and this advanced fabric can comprisea compression fabric. The advanced fabric aids in the correctpositioning of the ballistics and anti-fatiguing of the wearer andassists in providing an armor-enhanced under-clothing that iscomfortable, easy to customize and ergonomically superior over priordevices.

With regard to cooling, the present disclosure relates, in part, to anactive cooling subsystem that provides cooling via positive airpressure. The human body cools itself through the evaporation ofperspiration. The cooling process is sped up and made more efficientwhen the perspiration is exposed to air flow, for example, like using afan to simply move air onto a perspiring body. According to the presentdisclosure, positive air pressure can be provided via an external pumpthat pumps fluid such as air through a multitude of purposely placedperforated tubes. The tubes can be placed in and/or around a base layerand/or a spacer mesh article of clothing, allowing for comfort andunrestricted air flow from the tubing. In various embodiments, theperforated tubing can target specific areas such as the sternum of thechest and the spine region of the back where most of the blood flows inorder to cool down the core temperature. According to variousembodiments, multiple base layers are employed along with the coolingsubsystem and ballistic inserts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 show front and back views of one embodiment of a topelement as provided by the system of the present disclosure, with thetop element being inverted so as to show the interior surface thereof.

FIGS. 3 and 4 show front and back views of an alternative embodiment ofa top element as provided by the system of the present disclosure.

FIGS. 5 and 6 show front and back views of an alternative embodiment ofa top element as provided by the system of the present disclosure.

FIGS. 7 and 8 show front and back views of an alternative embodiment ofa top element as provided by the system of the present disclosure.

FIGS. 9 and 10 show front and back views of one embodiment of a bottomelement as provided by the system of the present disclosure.

FIGS. 11 and 12 show front and back views of an alternative embodimentof a bottom element as provided by the system of the present disclosure.

FIGS. 13 and 14 show front and back views of an alternative embodimentof a bottom element as provided by the system of the present disclosure.

FIGS. 15 and 16 show front and back views of an alternative embodimentof a bottom element as provided by the system of the present disclosure.

FIGS. 17 and 18 show front and back views of an alternative embodimentof a bottom element as provided by the system of the present disclosure.

FIGS. 19 and 20 show front and back views of an alternative embodimentof a top element as provided by the system of the present disclosure.

FIGS. 21 and 22 show front and back views of one embodiment of a topelement as provided by the system of the present disclosure.

FIG. 23 shows front and back views of a top element in accordance withone embodiment of the present disclosure.

FIG. 24 shows front and back views of an inverted top element inaccordance with another embodiment of the present disclosure.

FIGS. 25 and 26 are schematic left-side view diagrams illustrating oneembodiment of the chest portion and first pocket bag in accordance withthe present disclosure.

FIGS. 27 through 30 show front and back views of a long sleeve shirt inaccordance with aspects of the present disclosure.

FIG. 31 is a diagram illustrating a sequence of articles donned on thewearer in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE PRESENT DISCLOSURE

The presently disclosed subject matter now will be described more fullyhereinafter with reference to the accompanying drawings, in which some,but not all embodiments of the presently disclosed subject matter areshown. Like numbers refer to like elements throughout. The presentlydisclosed subject matter may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. Indeed, many modifications andother embodiments of the presently disclosed subject matter set forthherein will come to mind to one skilled in the art to which thepresently disclosed subject matter pertains having the benefit of theteachings presented in the foregoing descriptions and the associateddrawings. Therefore, it is to be understood that the presently disclosedsubject matter is not to be limited to the specific embodimentsdisclosed and that modifications and other embodiments are intended tobe included within the scope of the appended claims.

Example embodiments such as disclosed herein can incorporate a systemhaving a processor and an associated memory storing instructions that,when executed by the processor, cause the processor to performoperations as described herein. The system can be embodied as a server,for example. It will be appreciated that reference to “a”, “an” or otherindefinite article in the present disclosure encompasses one or morethan one of the described element. Thus, for example, reference to aninsert encompasses one or more inserts, reference to a base materialencompasses one or more base material layers and so forth.

FIGS. 1 through 31 illustrate different embodiments of the body armoraspects of the present disclosure. As shown in the embodiment of FIG. 1,the front side 14 of one embodiment of a top element 12 of the system ofthe present invention includes a suitably-sized interior pocket 16within a base material 17 for receiving a suitably-sized front torsoballistic panel 18. In embodiments, the base material 17 comprises acompression fabric designed to snugly fit the wearer with 100% bodycontact. As such, the base material 17 provides a material with hightenacity stretch which provides muscles with a firm compression fit thatlessons vibrations, reduces fatigue, and keeps muscles energized. Thefabric can be formed in a knit construction, for example, using a seriesof gradient fibers with an open knit inner surface to create a moisturetransfer environment.

The arm elements 20 also include respective suitably-sized interiorpockets 22 for receiving respective suitably-sized forearm ballisticpanels 24. The pockets 16, 22 generally include an opening through withpanels can be inserted and removed. This facilitates customization ofthe anti-ballistic properties of the present invention, as heavier andthicker panels may be needed for some engagements, while lighter andthinner panels may be needed for other engagements. In anotherembodiment, the pockets 16, 22 are constructed with panels retainedtherein, and then sealed so that the panels remain permanently part ofthe top element. The pockets can comprise a variety of materials,including compression fabric, or alternatively a static fabric materialretaining greater strength and resisting movement more than compressionfabric.

As shown in the embodiment of FIG. 2, the back side 15 of the topelement 12 includes a suitably-sized interior pocket 26 for receiving asuitably-sized back torso ballistic panel 28. As FIGS. 1 and 2 show theinterior surface 13 of the top element, it will be appreciated that thepockets 16, 22 and 26 are on the interior and are not generallyaccessible from the exterior of the top element, which assists in theconcealability and comfort of the present invention.

As shown in the embodiment in FIGS. 3 and 4, the top element can includeepaulets 30 over the shoulder area, wherein the epaulets 30 are formedwith an interior surface that forms a channel through which strapmembers 32 and clip members 34 can extend. The strap 32 and clip 34members can be used to retain additional panels 36 within or over thesurface of the base material 17.

FIGS. 5 and 6 show additional front 14 and back 15 sides of a topelement 12 of a system embodiment, similar to those shown in FIGS. 1 and2, respectively, with like numbers representing like elements therein.FIGS. 5 and 6 further show custom-sized interior hip-side pockets 40within the base material for receiving a custom-sized side ballisticpanel 42. Such panels 42 protect the user's side and hip areas and,similar to the front and back panels described above, provide for a snugfit which engages the wearer's body and does not, for example, protrudeso far as to hinder the wearer's ability to quickly access firearms orother materials that may be attached somewhere on the wearer'souterwear.

FIGS. 7 and 8 show front 14 and back 15 sides of a sleeveless topelement 12 with elements corresponding to those shown and described inconnection with FIGS. 1 through 6. Other top, bottom and groin areasections can be seen in FIGS. A through G, for example.

FIGS. 9 through 18 represent different embodiments of a bottom element50 of the present disclosure, with FIGS. 9, 11, 13, 15 and 17representing the front side 52 of the bottom element 50 and FIGS. 10,12, 14, 16 and 18 representing the back side 54 of the bottom element50. The base material 55 of bottom element 50 comprises a similarmaterial and/or the same material as the compression fabric describedabove with regard to base material 17 of top element 12. As representedin FIGS. 9 and 10, leg pockets 56 are provided to receive custom-sizedleg protective ballistic panels 58. The panels 58 protect at least thewearer's femoral artery. The pockets 56 can comprise static materialsimilar to that described above in connection with pockets 16, 22 inFIGS. 1-2.

FIGS. 11 and 12 show embodiments with protective elements 58 on thefront 52 and back 54 sides of the bottom element 50. FIGS. 13 and 14show embodiments similar to FIGS. 11 and 12, with the same referenceelements, and with an additional crotch protective element 60 retainedwithin a suitably-sized pocket 62 therearound.

FIGS. 15 and 16 show further enhanced embodiments of the bottom element50 of the present disclosure, with the front side 52 showing hip guards66 within hip pockets 64, in addition to crotch protective element 60and leg protective panels 58 as illustrated and described above.Further, FIG. 16 shows tailbone protective element 72 within tailbonepocket 70 and gluteal protective elements 74 within gluteal pockets 76.

FIGS. 17 and 18 show embodiments of the bottom element 50 of the presentdisclosure in long pants-like form. Similar reference numbers apply aslabeled and described above.

FIGS. 19-22 show additional embodiments of the top element 12 of thepresent disclosure. Outer arm internal pockets containing ballisticinserts 80, waistline internal pockets containing ballistic inserts 82and upper torso under arm pockets containing ballistic inserts 84 areshown therein with respect to a long sleeve embodiment 85 in FIGS. 19-20and a short sleeve embodiment 88 in FIGS. 21-22.

In operation, a wearer of embodiments of the presently disclosed systemand devices may select a previously installed version, where ballisticpanels are already selected and sewn in, or where ballistic panels arealready inserted into the top and bottom elements. The selection can bemade according to the wearer's size (e.g., small, medium and large).Alternatively, the wearer may select the top and bottom elements withoutany ballistic panels installed, put on the top and bottom elements, andthen install appropriate ballistic elements in the available pockets asdesired for an anticipated engagement. It will be appreciated that thepockets can be openable and sealable using hook and loop type fasteners,or other appropriate fasteners to enable quick assembly anddis-assembly. Accordingly, one aspect provides a protective clothingsystem with a standardized set of pockets which may or may not be fullyemployed for a given engagement, but which do not reduce the ergonomicdesign and comfortable fit, regardless of whether the pockets are filledwith suitable ballistic material.

The ballistic material can comprise, for example, layers of fibers thatmay comprise a high molecular weight polyethylene material, an aramidfiber, a combination of high performance fibers, or a non-woventhermoplastic composite. Commercially available embodiments of theballistic material are known as Dyneema™ and Spectrashield™, forexample. Other embodiments in accordance with the present disclosure arelighter weight unidirectional material and are capable of withstandingthe penetration of at least one of the following projectile types: a 9mm, 124 grain, FMJ projectile impacting the unidirectional material at avelocity of not less than 1,400 feet per second; and a 7.62×39, 124grain, mild steel core projectile impacting the unidirectional materialat a velocity of not less than 2,400 feet per second. In variousembodiments, the unidirectional material can be provided with an arealdensity of approximately 1.60 to approximately 2.10 pounds per squarefoot and can comprise not more than 15% by weight of matrix resin.Further, embodiments of the unidirectional material can comprise fromapproximately eighty-five to approximately one hundred sub-plies ofunidirectional material joined together by pressing, and wherein theunidirectional material passes the level III-A penetration resistancetest. In various embodiments, the unidirectional material can beprovided with eighty to ninety percent of the material weight in onedirection.

The present disclosure allows for the ballistic or other fabric inserts(e.g., as assessed by potential threat) to be sewn into or placed in apocket or sleeve, for example. The present disclosure also protects theend user from sand, ballistic fragments, etc., as a secondary layer. Invarious embodiments of the present disclosure, the tops or bottoms inany configuration will cover areas that traditional body armor does not.As such, an end user can wear the top or bottoms of the presentdisclosure under their traditional body armor and the tops and bottomswould have extra protection in the areas that the body armor does notcover. Optionally, there may be additional protection for the lowerabdominal area, arms, under arms, upper legs, etc.

As such, the presently disclosed system and devices can conceal thearmor, keep the armor or protection in the correct place, allow it tofit a great range of people, allow for multiple overlap points forextreme comfort, provide interchangeable armor components in order toadjust for size, and allow the tops and bottoms in one size to adjustwithin the pocket or sleeve so that the same component can permitdifferent thickness inserts to be employed.

In the embodiment as shown in FIGS. 23 and 24, for example, the presentdisclosure provides an article 100 of under-clothing, comprising a topelement 102 comprising a compression fabric or spacer mesh material,with the top element 102 having front 104 and back 106 exteriorsurfaces, and front 108 and back 110 interior surfaces. The article 100further includes a harness element 112 comprising, for example, anon-compression, static material secured to and extending from the frontinterior surface 108 to the back interior surface 110 of the top element102. The top element 102 further includes a neck area 111 forming anopening indicated at 113, left shoulder interior 114 and exterior 116surfaces, and right shoulder interior 118 and exterior 120 surfaces. Theharness element 112 includes a first strap element 122 secured to theright shoulder interior surface 118, and a second strap element 124secured to the left shoulder interior surface 114.

The first strap element 122 has a first strap length and is secured tothe right shoulder interior surface along substantially the entire firststrap length. Similarly, the second strap element 124 has a second straplength and is secured to the right shoulder interior surface alongsubstantially the entire second strap length.

The harness element 112 further includes a chest portion 126 secured atleast in part to the first 122 and second 124 strap elements and furthersecured to the front interior surface 108 of the top element 102. Asillustrated in FIG. 23 and in the schematic drawing of FIG. 25, thechest portion 126 can be secured by sewing a seam 127 that connects thechest portion 126 to the front interior surface 108 of the top element102. In one embodiment, the chest portion is secured to the frontinterior surface 108 along the upper perimeter boundary of the chestportion, which is shown along seam 127 in FIG. 23 as a substantiallyinverted U-shaped seam. Further, the chest portion 126 can comprise atwo-ply static fabric element that provides a durable and strongmaterial for the purposes of securely retaining ballistic-resistantmaterial as described hereinafter. In one embodiment, the harnesselement comprises a static material that does not stretch. Such amaterial can be considered a “jersey mesh” material in accordance withone embodiment. By not stretching, any armor inserted into the pocketbag portions described herein will not be permitted to bounce around.The bouncing of armor inserts is undesirable because it can reduceeffectiveness, comfort and desire for the user to employ armor. Thefirst or back ply 128 of the chest portion 126 is retained against thetop element 102 via seam 127, while the second or front ply 129 of thechest portion otherwise hangs freely over a first pocket bag portion 130provided as part of the harness element 112.

The first pocket bag 130 includes a back ply portion 131 and a front plyportion 132, and can accommodate the insertion or removal of ballisticinserts. In one embodiment, the back ply portion 131 of the first pocketbag 130 is integrally formed with the back ply 128 of the chest portion,but is generally not secured to the top element 102 (except optionallyat attachment points 145) and hangs freely from the chest portion. Thefront ply portion 132 similarly hangs freely but is not integrallyformed with the front ply portion 129 of the chest portion 126 of theharness element. Rather, the front ply portion 132 of the first pocketbag 130 includes a rim 139 (illustrated by dashed arrow in FIG. 23, andin FIG. 26), and the rim 139 of the front ply portion, as well as theouter side edges 141 and bottom edge 143 of the first pocket bag 130 aregenerally not secured to the top element 102, except optionally atattachment points 145 shown in FIG. 23, which can correspond to thepoints of intersection of the rim 139 and outer side edges 141 of thefront ply portion 132 of the first pocket bag. As shown in FIG. 26, forexample, the front ply 129 of the chest portion 126 can be lifted (e.g.,by hand), and the rim 139 and/or front ply 132 of the first pocket bag130 can be pulled away from the back ply 131 so as to create an opening133 to insert or remove a ballistic insert 135. As illustrated in FIG.25, the rim 139 of the front ply portion 132 of the pocket bag 130 canextend above the bottom edge 121 of the front ply 129 of the chestportion 126 when both ply portions 129, 132 are in the rested position,which results in the front ply 129 of the chest portion 126 overlappingthe front ply 132 of the pocket bag 130, which can thereby assist insecurely retaining the ballistic insert within the open area inside thepocket bag and the chest portion. It will be appreciated that the pocketbag 130 can be a separable component that is not integrated with thechest portion of the harness element 112 but is rather connectable anddisconnectable using a zipper-type connection, hook-and-loop typeconnection or other type of temporary connection.

As further shown in FIGS. 23 and 24, the harness element 112 includes aback portion 138 secured to the first 122 and second 124 strap elementsand further secured to the back interior surface 110 of the top element102. In one embodiment, the back portion is secured to the strapelements and the interior surface 110 of the top element 102, and thestrap elements 122, 124 are secured to the interior surface 110 of thetop element 102, such as by sewing a seam 140, for example. The harnesselement 112 further includes a second pocket bag 142. In one embodiment,the back portion 138 and the pocket bag 142 each comprise separatetwo-ply constructions similar to the chest portion 126 and pocket bag130, respectively, described above. In one embodiment, and similar tothe arrangement described above for the front pocket bag 130, the backply portion of the second pocket bag 142 is integrally formed with theback ply of the back portion 138, but the second pocket bag 142 isgenerally not secured to the top element 102 (except optionally atattachment points 151 shown in FIG. 23) and hangs freely from the chestportion. The front ply portion of the second pocket bag 142 similarlyhangs freely but is not integrally formed with the front ply portion ofthe back portion 138 of the harness element 112. Rather, the front plyportion of the second pocket bag 142 includes a rim similar to thatshown at 139 for first pocket bag 130, and the rim of the front ply andthe outer perimeter (including a bottom edge and side edges) of thesecond pocket bag 142 are generally not secured to the top element 102,except optionally at attachment points 151 shown in FIG. 23, which cancorrespond to the intersection points of the second pocket bag sideedges and the rim of the front ply of the second pocket bag.

One or more ballistic inserts can be inserted into and removed from thesecond pocket bag 142 and the opening created by the two plies of theback portion 138, similar to the process described and shown inconnection with the first pocket bag 130 and chest portion 126 in FIG.26, for example. It will be appreciated that the pocket bag 142 can be aseparable component that is not integrated with the chest portion of theharness element 112 but is rather connectable and disconnectable using azipper-type connection, hook-and-loop type connection or other type oftemporary connection.

As further shown in FIGS. 23 and 24, the top element 102 furtherincludes a left side portion 150 comprising left side interior 152 andexterior 154 surfaces, and a right side portion 156 comprising rightside interior 158 and exterior 160 surfaces, and further including afront portion 162 comprising the front interior 108 and exterior 104surfaces. The front portion 162 of the top element 102 is releasablysecured to the left side portion 150 using a left side securing element170 and is further releasably secured to the right side portion 156using a right side securing element 172. In one embodiment of thepresent invention, the left side 170 and right side 172 securingelements comprise slide fastener (i.e., Zipper™) elements, allowing theuser to zip and unzip the front portion 162 from the side portions 150,156 to allow easy access to the front pocket element 132 of the presentinvention.

It will be appreciated that embodiments of the protective clothingsystem and devices disclosed herein thus provide a customizable,scalable, armor-enhanced clothing system that conforms moresubstantially to the user's body, with a thinner and lighter armorprofile, and with better protection over every critical body area indifferent stages as selected by the user. The present disclosure furtherprovides such devices whereby the top element comprises an outercompression fabric layer with an inner non-compression fabric harnesselement.

With regard to the cooling sub-system of the present disclosure,positive air pressure can be provided via an external pump that pumpsfluid such as air through one or more purposely placed perforated tubes.The tubes can be merged into and/or placed adjacent a base material,such as a compression fabric or spacer mesh material, allowing forcomfort and unrestricted air flow from the tubing. The spacer meshmaterial can be embodied as three separate layers of fabric knittogether, such as a face and a back connected by a monofilament yarn toproduce a connecting cushion-type layer. Each layer can be knitsimultaneously by a single machine. As shown in FIGS. 27 through 31, forexample, a pump 300 can be secured to a tube 305 that may be perforated,such that when the pump operates, air is pressed through the tubing andexits different sections of the tubing based on the perforation therein,thereby providing an air source between the armor inserts and the basematerial and/or the user's skin. In various embodiments, such as shownin FIGS. 29 and 30, for example, the perforated tube 305 can be alignedwith the sternum 307 of the chest and the spine region 309 of the backwhere most of the blood flows in order to cool down the coretemperature. The tube can be provided as a flexible hollow material andthe pump can operate automatically or manually. In various embodiments,the pump is battery operated.

As shown in FIG. 31, the tube 305 includes a main portion or trunk 330and branches 307, 309 extending from the trunk 330. A splitter 333separates the trunk 330 into the branches 307, 309 and permits airflowing from the pump 300 and trunk 330 to flow through both branches307, 309. It will be appreciated that multiple splitters and additionalbranches of tubing can be employed in accordance with additionalembodiments of the present disclosure. In various embodiments, thetubing is formed of a plastic or rubber material.

In various embodiments, the base material (e.g., compression fabric orspacer mesh material) has a front side and a back side. As further shownin FIG. 31, in certain embodiments, a first base material 212 can beworn by the user 250 next to the user's skin. The tube 305 and pump 300can then be positioned over and against the first base material 212. Asecond base material 214 can then be positioned over and against thetubing 305. The pump 300 may lie between the first 212 and second 214base material or may extend outwardly thereof. Regardless, the tube 305is maintained between the first 212 and second base material 214. Athird base material 216 may then be positioned over and against thesecond base material, according to various embodiments. The third basematerial 216 can be provided with one or more pockets 220, 224 to houseone or more ballistic inserts 218, 222 as described above. When thethird base material 216 is donned, the tube 305 is thus separated fromthe third base material 216 with inserts 218, 222 by the second basematerial 214. In this way, the tubing has adequate space and theperforations permit air flow along the path of the tubing to cool theuser's body. In various embodiments, the first 212, second 214 and third216 base material comprise compression fabric. In various otherembodiments, the first 212, second 214 and third 216 base materialcomprise spacer mesh material. In still other embodiments, the first212, second 214 and third 216 base material comprise compression fabricor spacer mesh material. In a specific embodiment, the first basematerial 212 comprises spacer mesh material and the second 214 and third216 base material comprise compression fabric. In such embodiment, thespacer mesh material as the first base material 212 provides additionalopenings through which cooling air may flow to the user's skin.

In some embodiments, the system employs the first base material 212,tube 305 and pump 300 and third base material 216 with one or morepockets and one or more inserts, without the second base material 214.

In various embodiments, the spacer mesh can be provided with rigidspacing inserts to increase space between the spacer mesh adjacent theuser's body and the tubing. Such inserts can form a type of frame forthe spacer mesh as the first base material 212, for example, and theincreased space provides for additional cooling of the user duringoperation.

The present disclosure describes numerous embodiments, and theseembodiments are presented for illustrative purposes only. Theseembodiments are described in sufficient detail to enable those skilledin the art to practice what is disclosed herein, and it will beappreciated that other embodiments may be employed and that structural,and other changes may be made without departing from the scope or spiritof the present disclosure. Accordingly, those skilled in the art willrecognize that the presently disclosed embodiments may be practiced withvarious modifications and alterations. Although particular featuresdisclosed herein can be described with reference to one or moreparticular embodiments or figures that form a part of the presentdisclosure, and in which are shown, by way of illustration, specificembodiments of the invention, it will be appreciated that such featuresare not limited to usage in the one or more particular embodiments orfigures with reference to which they are described. The presentdisclosure is thus neither a literal description of all embodiments nora listing of features of the invention that must be present in allembodiments.

1. A clothing system, comprising: a first base material formed for wear; a cooling subsystem comprising: a perforated tube positionable against the first base material, and a pump configured to pump fluid through the perforated tube; and a second base material formed for wear, wherein the second base material is positionable over the cooling subsystem.
 2. The clothing system of claim 1, further comprising a third base material formed for wear, wherein the third base material comprises a pocket and wherein the third base material is positionable over the second base material.
 3. The clothing system of claim 2, further comprising a ballistic insert maintained within the pocket.
 4. The clothing system of claim 1, wherein the first and second base material comprise a compression fabric.
 5. The clothing system of claim 2, wherein the third base material comprises a compression fabric.
 6. The clothing system of claim 1, wherein the first base material comprises a spacer mesh material.
 7. The clothing system of claim 6, further comprising a rigid insert secured to the spacer mesh material so as to increase space between the first base material and the perforated tube.
 8. The clothing system of claim 1, wherein the perforated tube comprises a trunk and a plurality of branches extending from the trunk.
 9. The clothing system of claim 1, further comprising a splitter separating the trunk into the plurality of branches.
 10. The clothing system of claim 1, wherein the pump is configured to pump air through the perforated tube.
 11. The clothing system of claim 3, wherein the ballistic insert comprises a unidirectional material with an areal density of approximately 1.60 to approximately 2.10 pounds per square foot.
 12. The clothing system of claim 11, wherein the unidirectional material comprises from approximately 85 to approximately 100 sub-plies of unidirectional material joined together.
 13. The clothing system of claim 1, wherein the first and second base material are formed for wear over a user's upper body.
 14. A clothing system, comprising: a first base material formed for wear; a cooling subsystem comprising: a perforated tube positionable against the first base material, and a pump configured to pump fluid through the perforated tube; a second base material formed for wear, wherein the second base material is positionable over the cooling subsystem, wherein the second base material is formed with a pocket; and a ballistic insert maintained within the pocket.
 15. The clothing system of claim 14, wherein the ballistic insert comprises a unidirectional material comprising an areal density of approximately 1.60 to approximately 2.10 pounds per square foot.
 16. The clothing system of claim 15, wherein the unidirectional material comprises eighty-five or more sub-plies joined together by pressing.
 17. The clothing system of claim 14, wherein the ballistic insert comprises not more than fifteen percent by weight of matrix resin. 